Hobart Aluminum Guide
Hobart Aluminum Guide
Hobart Aluminum Guide
ITW Welding
The
It is not merely the innovative manufacturing methods and techniques which make the Hobart product
best in class. The quality and meticulous attention to detail in every facet of delivering the product into
the customers hands are also a high priority. It is a well known fact that aluminum requires special procedures to work with and therefore the aluminum welding material must be able to meet all requirements.
The key criteria in the Hobart product are as follows:
Extreme cleanliness (able to exceed the AWS porosity standard)
Outstanding feedability
Superior arc stability
Superior arc starts
Excellent welder appeal
Repeatability and consistency
Wire diameter control (1/10th of allowed AWS specification)
All these features available in a wide range of alloys
Plant and product certifications ISO 9001, AWS, CWB, ABS, ASME, CE, VdTUV and DB
ALLOY
1100
4043
4047
4943
5356
5554
5183
5556
5087
MIG/TIG
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
The quality does not end here, the product then needs to be packaged and delivered to the customer.
To ensure the product arrives in the same condition when it left the factory, great detail has been given
to the packaging. Some of the unique features are as follows:
Spools and Baskets (MIG):
A sturdy 12 spool double walled reusable box with top entry
No taping of the box flap due to snug fitting closure
A sturdy wire basket spool; the strongest in the industry
Heavy weight plastic bag for better atmospheric protection
8 5 lb., 12 16 lb. and 22 lb. plastic spools available
Unique alloy selection guide on side of all boxes (MIG and TIG)
Straight Lengths (TIG):
Revolutionary TIG box with zipper style end cap for removal of a few rods then replaced for protection
Inner liner in TIG box adds to sturdiness, provides snug fit, rods stretch wrapped in bundles eliminates
moisture and fretting corrosion
Master TIG carton holds 4 boxes
Drums
300# drum, 100# drum and 50# ergo pac drum provide tangle free feeding with minimal utilization of
dispensing systems
Multi-sided for extra sturdiness, adapts to most currently available cones
Double walled with plastic sealable bag between walls for moisture protection
Unique self contained pallet for maneuverability eliminates use of lifting straps which can damage drums
and wire
Two individual drums per skid
Considering all the above including an extensive range of welding filler metals with the unparalleled
technical expertise and services, Hobart Aluminum is the only choice for your aluminum welding solutions.
Welding
Procedure
Specification
General Technical Assistance for Aluminum Design Engineers, Process Engineers & Welders
All commercial welding operations should have a written Welding Procedure Specification (WPS) for each weldment that
is produced. This booklet provides guidance in determining the key technical elements required to produce a reliable WPS
and achieve a successful welding outcome.
The following uses the flow of a typical Welding Procedure Specification (WPS) as the guideline for its organization,
with a sample WPS form shown on page 3.
Index:
Weld Preparation
& Treatments
Filler Metal
Base Metal
Specifications
Problem
Solving
Welding
Procedures
Information
Sources
Problem Solving
Welding Procedures
Information Sources
Page 37.........Welding Design Information and Technical
Assistance
Page 38.........Conversion Tables
Base Metal
AWS M-No.
Alloy
Welding Procedures
Temper Section Thickness Process:
MIG
TIG
Shielding Gas:
Type
Flow Rate
Filler Metal
AWS F-No.
AWS Class
Welding wire diameter
Welding wire type:
MIG
TIG
Cleaning:
Oxide removal
Hydrocarbon/contaminant removal
Etch
Solvent
Wash
Interpass cleaning:
Yes
No
Interpass cleaning method
Preheat:
Yes
No
Preheat temperature
Interpass temperature limit
Remove
Mixture
Gas Cup Size
Backing:
Type
Permanent
Approved
Approved
Welding
Procedure
Specification
Specification No.
Revisions
PQR Numbers
Certification Specifications & Codes
Progression:
Weave
Other
Method
Travel
speed
Base Metal
Alloy And Temper Designations
Aluminum Alloy Compositions - Aluminum Association Numbering System
Base Metal
Wrought Alloys
1xx.x
99.00% Minimum Aluminum
2xx.x Copper
3xx.x
Silicon + Copper and/or Magnesium
4xx.x Silicon
5xx.x Magnesium
6xx.x
Unused Series
7xx.x Zinc
8xx.x
Tin
9xx.x
Other Elements
-W
-T
As fabricated
Annealed
Strain hardened
- H1
- Strain hardened only
- H2
- Strain hardened and partially annealed
- H3
- Strain hardened and stabilized
- H4
- Strain hardened and lacquered or painted
Solution heat-treated
Thermally treated
- T1 - Naturally aged after cooling from an elevated temperature shaping process
- T2 - Cold worked after cooling from an elevated temperature shaping process
and then naturally aged
- T3
- Solution heat-treated, cold worked, and naturally aged
- T4
- Solution heat-treated and naturally aged
- T5
- Artificially aged after cooling from an elevated temperature shaping process
- T6
- Solution heat-treated and artificially aged
- T7
- Solution heat-treated and stabilized (over aged)
- T8
- Solution heat-treated, cold worked, and artificially aged
- T9
- Solution heat-treated, artificially aged, and cold worked
- T10
- Cold worked after cooling from an elevated temperature shaping process
and then artificially aged
- TX51 - Stress relieved by stretching
- TX52 - Stress relieved by compression
1xxx (pure)
1350
1100
- F, -O
-O, -H14
2xxx (Cu)
2219
-T6
3xxx (Mn)
3003
-O, -H12
5xxx (Mg)
5052
-O, -H34
5454
-O, -H34
5086
-H32, -H34
5083
-H32
5456
-H32
6xxx (Mg/Si)
6061
6063
6005
6009
6111
-T6, -T651
-T5
-T5
Base Metal
Formability, corrosion resistance, and low cost (roll forms, auto, trailers,
truck trailer sheeting)
Elevated temperature applications (wheels)
Strength and toughness (shipbuilding, boats)
High strength, good saltwater corrosion resistance (shipbuilding), cryogenic application
High strength-to-weight ratio (pressure vessels, tanks)
High strength and toughness (truck trailer, rail cars)
Strength and good anodizing properties (architectural applications, automotive trim)
7xxx (Zn)
7005
Copper-free 7xxx alloys which are good for extrusions.
7021
-T53, -T63
Good toughness and formability. (automotive, truck, ships railings,
7029
bumper supports, sports products such as bats, bikes etc.)
7146
ote: Alloys 2024, 7075 and 7050 are considered non-weldable by the arc welding process. See page 9.
N
Typical Tempers
Non-Heat Treatable
Heat Treatable
2xx.x
201.0
Limited Weldability
206.0
Limited Weldability
224.0
Limited Weldability
3xx.x (Si+Cu and/or Mg)
319.0
x Elevated temperature strength (auto pistons)
333.0
x Elevated temperature strength (diesel pistons)
354.0
x
(auto accessories, crank cases)
C355.0
x (aircraft, missiles)
A356.0 (356.0)
x
General purpose structural
A357.0
x High strength (aerospace)
359.0
x High impact strength (aircraft structural)
380.0
x
General purpose
4xx.x (Si)
443.0
x
Pressure tight (marine, valves)
A444.0
x
5xx.x (Mg)
511.0
x Good anodizing properties (architectural)
512.0
x
(fittings, cooking utensils)
513.0
x
514.0
x Excellent corrosion resistance (chemical processing, marine)
7xx.0 (Zn)
710.0
x Good brazing characteristics
712.0
x (general purpose, corrosion resistant applications)
Base Metal
The 6xxx series base metals have low alloy content and are easy for mill product fabricators to form into extrusions,
tubing, forgings and other shaped products and then to heat treat to obtain high mechanical properties, making them
economical to produce. The 5xxx series base metals have high alloy content and because of their strain hardening
and higher flow stress characteristics are more costly to fabricate into shapes. However the 5xxx series base metals
are economically rolled into sheet and plate and roll formed into shapes when specific shapes are desired.
The 6xxx series base metals obtain their maximum mechanical properties through heat treatment and aging. The
aluminum metal matrix is strengthened by the precipitation of the alloying elements as intermetallic compounds whose
size and distribution throughout the matrix is carefully controlled through precise thermal operations. When the
6xxx series base metals are welded, the microstructure in the HAZ is degraded and the mechanical properties are
typically reduced by 30 - 50%. Figure 1 on page 7 shows that 6061 and its most common filler metal 4043 both have
a typical annealed tensile strength of around 19 ksi. Depending on the heat input during the welding operation, the
base metal can be fully annealed for some distance from the weld, especially in areas being weld repaired.
The 5xxx series base metals obtain their maximum mechanical properties through alloying element solid solution
strengthening and additional strength is gained from cold working. The welding operation does not affect the solid
solution strengthening of the base metal, only the cold working portion of the strength is lost in the heat affected zone
transforming it to the annealed condition. Figure 1 on page 7 shows that the typical annealed tensile strength of 5083
base metal is 43 ksi.
Figure 1 on page 7 compares the loss of strength in the heat affected zone of welded 6061-T6 and 5083-H321 wrought
base metals.
Figure 2 on page 7 shows the loss of strength in the heat affected zone of the as-welded 6061-T4 and -T6 base metals
compared with post-weld aging.
The chart on page 7 shows the basic alloying elements and typical ultimate tensile strengths in the non-welded and
as-welded conditions for the most frequently welded 6xxx and 5xxx series base metals. The charts illustrate and are
supported by the following important points:
The loss of as-welded strength in the 5xxx base metals is significantly less than that of the 6xxx base metals.
The 6xxx base metal properties shown are dependent on a minimum of 20% dilution of 6xxx base metal into the
4043 filler metal weld pool. The 5xxx base metals when welded with 5xxx filler metals are not dependent on dilution.
The 6xxx base metals have 30% higher thermal conductivity than the 5xxx base metals making it more difficult
to produce consistent quality welds in the 6xxx base metals. Therefore 6xxx base metals require higher heat input
to achieve penetration and this can result in increased distortion of the welded structure.
4
5
6xxx base metals welded with 5xxx filler metals are more solidification crack sensitive than 5xxx base metals
welded with 5xxx filler-metals. See page 10.
As-welded 5xxx base metals welded with 5xxx filler metals have higher ductility, toughness, and crack propagation
resistance than as-welded or post-weld heat treated and aged 6xxx base metals welded with 4043.
The as-welded mechanical properties of the 6xxx base metals are very sensitive to welding variables such as heat
input and joint design whereas the 5xxx base metals are far less sensitive to these variables, making the 5xxx
as-welded results much more controllable.
Figure 2
Typical properties of 6061-T4 & T6
Base Metal
Base Metal
Typical UTS
&
%
%
(non-HAZ)
Temper
Si
Mg
ksi
Typical UTS
(welded)
ksi
6061
T6
0.6 1.0
T4 (PWA)
T6 (PWA)
T6 (PWH&A)
45
45
43
45
27
37
33
44
24
32
27
38
53
71
61
84
35
20
17
54
35
38
28
28
25
25
71
66
2.7
44
35
31
70
4.0
47
39
35
74
5.0
46
43
40
87
5.1
51
46
42
82
6063
T6
0.4 0.7
(PWA) - post-weld aged
(PWH&A) - post-weld heat treated and aged
5052
H32
2.5
H34
5454
H34
5086
H34
5083
5456
H116
Filler Metal
Guidelines For Selecting The Most Appropriate Filler Metal (4043 or 5356)
Selecting the correct filler alloy for aluminum is based on the operating conditions of the finished welded component. It is
therefore essential to have the answers to some basic questions prior to the selection of the most appropriate filler metal.
1.
2.
3.
4.
5.
Alloys 4043 and 5356 are used in over 85% of all aluminum weldments. If the technical requirements of the weld can
be met with either 4043 or 5356, use one of these two alloys because they are readily available and are the least
expensive to purchase. Also consider using the largest recommended diameter wire because the larger sizes are also
less expensive.
Filler Metal
When welding the 5xxx and 6xxx series base metals the following considerations should be made when selecting the
most appropriate filler metal:
For 6xxx series base metals, and 5xxx series base metals containing less than 3% Mg use either 4043 or 5356.
For 5xxx series base metals containing more than 3% Mg use 5356 filler metal and do not use 4043 filler metal.
For good anodized color matching use 5356.
For higher ductility and toughness use 5356. This will increase resistance to crack propagation.
For long term elevated temperature exposure above 150F use 5554 or 4043. Do not use 5356.
higher shear strength use 5356. A rule-of-thumb is that it takes three fillet passes of 4043 to equal the shear
For
strength of one pass of 5356.
For reduction of termination and shrinkage cracking use 4043 or 4047.
For reduction of welding distortion use 4043 or 4047.
For brighter welds with less welding smut use 4043.
better feedability through the welding gun use 5356. 5356 is twice as stiff as 4043 and therefore feeds better.
For
However, MAXALs 4043 has excellent feedability.
Note: For more detailed information on filler metal selection refer to the Hobart selection chart in the back of this book.
MAXAL4943
Alloy 4943 filler metal was designed to provide a high strength solution with the ease of welding and other advantages
of 4043. Alloy 4043 filler metal is a popular aluminum/silicon filler alloy for general purpose welding applications.
Alloy 4943 filler metal was formulated to be welded with the same weld procedure specifications as 4043 and 4643,
and does not depend upon dilution from the base metal during welding to increase the strength of the weld deposit,
while maintaining the same excellent corrosion characteristics, low melting temperature, low shrinkage rate, higher
fluidity, and low hot cracking sensitivity. Welds exhibit low welding smut and low discoloration. 4943 is heat-treatable
and exhibits strength levels superior to 4043 and 4643 in post weld age and post weld heat treat and age conditions.
Applications:
Post weld age, post weld heat treat & age applications
Sports products - scooters/bicycles
General repair and maintenance
Alloy 356 Castings
Ladders and frames
Filler Metal
Automotive/motorcycle frames
Aerospace hardware
Wheels
Ship decks
Furniture
Filler Metal
Explanation:
In the heat affected zone of the non-weldable 2xxx and 7xxx series alloys, low melting point elements are preferentially
precipitated into the grain boundaries which lowers and widens the solidification temperature range of the grain
boundary. Consequently, when arc welding these types of base metals, the grain boundaries become the last to solidify
and can easily crack due to solidification shrinkage stresses. In addition, the difference in galvanic potential between the
grain boundaries and the remainder of the grain structure in these alloys is increased, making them more susceptible to
stress corrosion cracking. These base metals are typically mechanically fastened rather than arc welded.
Note: Some of these base metals are presently being welded with the friction stir welding (FSW) process, which
operates at lower temperatures than arc welding and does not melt the base metal during welding thereby eliminating
solidification problems.
10
D1.2
ability
Cu Si Mn Mg Zn Cr Zr Range lb/in3 Anodized Al
Group F Color
Min.
ER1100
F21
0.12
11901215
0.098
Yellow
99.00
2014
C 4.4 0.8 0.8 0.5 9451180 0.101 Golden
2024 C 4.5 0.6 1.5 9451180 0.101 Golden
2219 nl
M24 B 6.3 0.3 0.17
10101190 0.103 Golden
3003 M21
A
1.2 11901210
0.099
Clear
3004 M21
A
1.1
1.0 11651210
0.098
Clear
ER4043
F23
5.0
10651170
0.097 Gray
ER4047
F23
12.0
10701080
0.096
D. Gray
ER4643
F23 4.2 0.2 10651170 0.097 Gray
ER4943
F23 5.2 0.4 10651170 0.097 Gray
6005 M23
A
0.5
0.75
0.5 11251210
0.097
Clear
6061 M23 A 0.25
0.6 1.0 0.20 10801205 0.098 Clear
6063 M23 A 0.4 0.7 0.20 11401210 0.097 Clear
6070 B
0.27
1.35
0.7
0.85
10501200
0.098
Clear
7075
1.60
2.5
5.6
0.30
8901175
0.10
Brown
A Readily weldable
B Weldable in most applications, requires a qualified welding procedure
C Limited weldability, caution; consult reference document before welding
High
Low
Low
Low
Low
(55)
(15)
(13)
(15)
(15)
5087
5183
5356
5554
5556
Good (25)
Good (25)
High (35)
High (40)
Good (25)
Toughness
Resistance
To Crack
Growth
Resistance
Min. Shear Strength
To
Fillet Welds (ksi)
Solidification
Cracking
Longitudinal
Transverse
Good
Low
Low
Low
Low
Good
Very Good
Excellent
Good
Very Good
Low (7.5)
Low (11.5)
Low (11.5)
Med. (13.5)
Med. (15.5)
Low (7.5)
Low (15.0)
Low (15.0)
Med. (20.0)
Med. (23.0)
Low (13)
Low (28)
High (38)
Med. (29)
Med. (35)
High
High
V. High
V. High
High
Good
Good
Good
Fair
Good
High (20.0)
High (18.5)
High (18.0)
Med. (17.0)
High (20.0)
High (30.0)
High (28.0)
High (26.0)
Med. (23.0)
High (30.0)
High (42)
High (41)
High (38)
Med. (33)
High (42)
11
Filler Metal
5005 M21 A 0.8 11701210
0.098 Clear
5050 M21 A 1.4 11551205
0.097 White
5052 M22 A 2.5 0.25 11251200 0.097 White
5083 M25 A 0.65 4.45 0.15 10651180 0.096 White
ER5183
F22 0.75 4.75 0.15 10751180 0.096 White
5086 M25 A
0.45 4.0 0.1 10851185 0.096 White
5087 0.90 4.85 0.15
0.15 10701175 0.096 White
ER5356
F22 0.12 5.0 0.12 10601175 0.096 White
5454 M22 A 0.8 2.8 0.1 11251200 0.096 White
5456 M25 A 0.8 5.2 0.1 10501180 0.096 White
ER5554
F22 0.75 2.7 0.12 11151195 0.096 White
ER5556
F22 0.75 5.1 0.12 10601175 0.096 White
Weld
Preparation
& Treatments
Store all welding wire and base metal in a dry location with a minimum temperature fluctuation.
Welding wire should preferably be stored in a dry heated room or cabinet.
Store metal vertically to minimize moisture condensation and absorption of water contamination
between layers.
Bring all filler and base metal materials into the welding area 24 hours prior to welding to allow them
to come to room temperature.
Keep welding wire covered at all times.
Joint Preparation
Dont use methods that leave a ground or smeared surface. For example, a circular sawed surface is weldable
while a band sawed surface leaves a smeared surface that may result in lack of fusion and should be filed to
remove smeared metal prior to welding. Using a course disc grinder is preferable to a wheel grinder, however,
if possible avoid the use of any type of grinder.
Dont use any lubricants in the joint preparation metal working process, if possible.
Dont use chlorinated solvents in the welding area because they may form toxic gases in the presence
of electric welding arcs.
Dont use oxyfuel gas cutting, carbon arc cutting or gouging processes, or oxyfuel flames to preheat.
These processes damage the heat affected area and promote the growth and hydration of the oxide film
present on the surface.
Use plasma arc cutting & gouging and laser cutting.
Mechanically remove the plasma arc and laser cut edges from 2xxx, 6xxx and 7xxx series alloys. The melted
edges of these alloys will contain detrimental solidification cracks and heat affected zone conditions.
Remove a minimum of 1/8 inch of metal from the cut edge. Use mechanical metal removal methods that
cut and remove metal chips.
Prepare and clean the joint prior to assembly. Degrease the surfaces with a solvent.
Use clean cloth such as cheese cloth or paper towels to solvent clean and dry a welding joint.
Dont use shop rags to clean welding joints and do not use compressed air to blow off the joint.
Compressed air contains moisture and oil contaminates.
Stainless steel wire brush the joint only after solvent cleaning. Wire brushing prior to cleaning embeds
hydrocarbons and other contaminates in the metal surface.
Stainless steel wire brush all metal that has been etched. The by-product residuals from etching must
be removed prior to welding.
Clean all wire brushes and cutting tools frequently.
12
Weld Backing
Temporary backing strips are usually made from copper, anodized aluminum, stainless steel, or various ceramic materials.
They are used to control penetration and are removed after welding. Care must be taken to prevent melting the backing
material into the weld puddle.
Permanent backing strips are always made from the same alloy as the base metal being welded. Refer to AWS D1.2 for
backing strip removal requirements.
Typically no root opening is used when using temporary backing material. A root opening is typically used when using
permanent backing material.
60
1/2
t/4
1/8-3/32
TEMPORARY
BACKING
13
Weld
Preparation
& Treatments
Preheating can be used to reduce the thermal effects of section size when welding base metals of dissimilar thicknesses.
Heat treatable base metals and 5xxx base metals containing more than 3% Mg should not be subjected to preheating and
interpass temperatures above 250 F (121 C) for more than 15 minutes. Refer to AWS D1.2.
Welding Procedures
Electrodes For Aluminum TIG Welding
Tungsten electrodes as specified in AWS A5.12
Thoriated
(1% yellow, 2% red)
Zirconiated (brown)
Ceriated (gray)
Lanthanated (black)
Note: The electrode tip for pure and zirconiated is usually formed into a smooth hemisphere. The 2% Ceriated and
11/2 % Lanthanated Tungsten Electrodes have become the most popular for aluminum welding. These electrodes
are ground to a blunt point, making sure to keep the grinding direction parallel to the length of the electrode.
Welding
Procedures
MIG:
TIG:
Warning: Helium content greater than 25% may cause arc instability, when TIG welding.
Pure argon is the most commonly used shielding gas. It is economical, has good arc cleaning properties, and produces
a clean weld. Argon is heavier than air and gives excellent shielding gas coverage in the flat position. The addition of
helium increases the ionization potential and the thermal conductivity of the shielding gas which produces greater heat
conducted to the base metal through the arc. This feature causes an increase in weld penetration, an increased width
of the weld root, and reduced porosity in the weld bead. The negatives of argon-helium gas mixtures are higher required
flow rates because of the lower density of the gas and increased cost. Helium also increases weld discoloration because
more magnesium is burned
in the arc at the higher arc
temperatures. The argon gas
shall have a minimum purity
of 99.997% and a dew point
Helium
Argon
Helium
Argon
Helium
of -76 degrees F or lower.
Penetration
deep / narrow
wider / hotter
Helium shall have a purity
of 99.995 % and a dew point
Mechanical properties
less affected
more affected
of -71 degrees F or lower.
Welding travel speed
slower
faster
Weld appearance
rippled
smoother
more
less
brighter / cleaner
more smut
Arc stability
stable
less stable
Porosity
more
less
Cleaning action
Weld appearance (color and
smut)
14
Argon
Root Opening
2t
TEMPORARY
BACKING
t/4
(A)
(B)
60 - 90
60 - 90
or 110
3/16
ROOT OPENING
ROOT OPENING
1/16-3/32
(D)
(C)
90
60
1/16-3/32
ROOT OPENING
1/8-3/32
TEMPORARY
BACKING
(E)
ROOT OPENING
(TYPICALLY ZERO)
1/2
t/4
(F)
60
ROOT OPENING
t
1/16
PERMANENT
BACKING
1 1/2
t up to 3/8
3/8 for t>3/8
PERMANENT
BACKING
(G)
1 1/2
t up to 3/8
3/8 for t>3/8
(H)
The chart below provides approximate welding parameters as a starting point only. Qualified welding
procedures utilizing tested practices should be developed for actual production weldments.
Amps
4xxx
Amps
5xxx
Volts
4xxx
0.030
1/16
90
100
20
18
260
300
3/32
110
120
22
21
350
400
3/64
1/16
1/8
130
140
23
21
450
500
3/16
150
160
24
22
550
600
1/4
175
185
24
22
650
700
1/16
90
100
23
21
300
350
1/8
130
140
24
22
400
450
1/4
170
180
25
23
500
600
3/32
110
120
25
24
170
220
1/8
150
160
26
25
270
330
1/4
190
220
26
25
320
370
3/8
220
230
27
25
390
450
1/4
200
210
26
24
170
200
3/8
230
240
27
25
200
230
1/2
260
270
28
26
240
270
3/4
280
290
29
27
260
300
1.00
300
310
30
28
280
320
Welding
Procedures
Base Material
Thickness Inches
0.035
Volts
5xxx
Wire Feed
Speed (ipm)
4xxx
5xxx
Wire Diameter
Inches
15
Welding
Procedures
Metal
Weld
Edge
Joint
Weld
Electrode
DC (EP)3 Arc
Argon Arc
Approx.
1
2
Thickness Position Preparation Spacing Passes Diameter (amps) Voltage3 Gas Flow Travel
Electrode
(inches)
(inches)
(inches)
(volts)
(cfh)
Speed
Consump.
(lb/100ft)
(ipm/pass)
1/16 F
None 1
.030
70-110 15-20 25
25-45 1.5
3/32
.030
70-110
15-20
25
25-45
3/32
None
.030-3/64 90-150
18-22
30
25-45
1.8
F,V,H,O
1/8
.030
110-130 18-23
30
23-30
1/8
F,V,H
0-3/32
30
24-30
F,V,H,O
3/16
30
18-28
3/16
F,V,H
0-1/16
35
24-30
F,V,H
0-1/16
3/64
140-180 23-27
35
24-30
0-1/16
2F
3/64
140-175 23-27
60
24-30
F,V
3/32-3/16 2
3/64-1/16 140-185
23-27
35
24-30
H,O
3/16
3/64
130-175 23-27
60
25-35
10
1/4
0-3/32
40
24-30
0-3/32
40
24-30
V,H
0-3/32
3F,1R 3/64
165-190 25-29
45
25-35
10
0-3/32
60
25-35
10
F,V
1/8-1/4 2-3
40
24-30
12
O,H
1/4
4-6
60
25-40
12
3/8
C-90
0-3/32
1F,1R 1/16
225-290 26-29
50
20-30
16
0-3/32
2F,1R 1/16
210-275 26-29
50
24-35
18
V,H
0-3/32
3F,1R 1/16
190-220 26-29
55
24-30
20
0-3/32
5F,1R 1/16
200-250 26-29
80
25-40
20
F,V
1/4-3/8 4
1/16
210-290 26-29
50
24-30
35
O,H
3/8
8-10
1/16
190-260 26-29
80
25-40
50
3/4
C-60
0-3/32
3F,1R 3/32
340-400 26-31
60
14-20
50
0-1/8
4F,1R 3/32
325-375 26-31
60
16-20
70
V,H,O
0-1/16
8F,1R 1/16
240-300 26-30
80
24-30
75
0-1/16
3F,3R 1/16
270-330 26-30
60
16-24
70
V,H,O
0-1/16
6F,6R 1/16
230-280 26-30
80
16-24
75
16
1
2
3
F,V,H,O
0.030
100-130
18-22
30
24-30
0.75
1/8
0.030-3/64 125-150
20-24
30
24-30
V,H
0.030
110-130
19-23
30
24-30
0.030-3/64 115-140
20-24
40
24-30
3/16
3/64
180-210
22-26
30
24-30
2.3
V,H
0.030-3/64 130-175
21-25
35
24-30
2.3
0.030-3/64 130-190
22-26
45
24-30
2.3
1/4
3/64-1/16 170-240
24-28
40
24-30
V,H
3/64
170-210
23-27
45
24-30
3/64-1/16 190-220
24-28
60
24-30
3/8
1/16
240-300
26-29
50
18-25
H,V
1/16
190-240
24-27
60
24-30
1/16
200-240
25-28
85
24-30
3/4
3/32
360-380
26-30
60
18-25
36
H,V
4-6
1/16
260-310
25-29
70
24-30
36
10
1/16
275-310
25-29
85
24-30
36
Welding
Procedures
1. Metal thickness of 3/4 in. or greater for fillet welds sometimes employs a double bevel of 50 degrees or
greater included angle with 3/32 to 1/8 in. land thickness on the abutting member.
2. F = Flat; V = Vertical; H = Horizontal; O = Overhead.
3. Number of weld passes and electrode consumption given for weld on one side only.
4.
For 5xxx series electrodes use a welding current in the high side of the range given and an arc voltage
in the lower portion of the range. 1xxx, 2xxx and 4xxx series electrodes would use the lower currents and
higher arc voltages. These considerations constitute a basis for the filler metal groupings in AWS D1.2:
F22 (5XXX), F23 (most 4XXX), F24, F25.
17
Welding
Procedures
Aluminum Weld
Edge
Root
Preheat Weld
Filler
Tungsten
Gas Cup Argon AC
Arc
Approx.
Thickness Position2 Prep. 3 Opening (F)4 Passes
Diameter Electrode Inside (cfh) (amps) Travel Filler Rod
(inches) (inches) (inches)
Diameter
Diameter Speed
Consumption
(inches)
(inches) (ipm)
(lb./100 ft)
1/16
F, V, H A or B
0-1/16
None
3/32
1/16-3/32 3/8
20
70-100
8-10
0.5
A or B
0-1/16
None
3/32
1/16
3/8
25
60-75
8-10
0.5
3/32
A or B
0-3/32
None
1/8
3/32-1/8
3/8
20
95-115
8-10
V, H
A or B
0-3/32
None
3/32-1/8 3/32
3/8
20
85-110
8-10
A or B
0-3/32
None
3/32-1/8 3/32-1/8
3/8
25
90-110
8-10
1/8
A or B
0-1/8
None
1-2
1/8-5/32 1/8
7/16
20
125-150 10-12
V, H
A or B
0-3/32
None
1-2
1/8
1/8
7/16
20
110-140 10
A or B
0-3/32
None
1-2
1/8-5/32 1/8
7/16
25
115-140 10-12
3/16
D-60
0-1/8
None
170-190 10-12
4.5
5/32
5/32
7/16
25
160-175 10-12
4.5
5/32
5/32
7/16
25
155-170 10-12
5/32
5/32
7/16
30
165-180 10-12
1/4
D-60 0-1/8
None
3/16
3/16-1/4 1/2
30
220-275 8-10
3/16
3/16
1/2
30
200-240 8-10
30
190-225 8-10
30
210-250 8-10
10
3/8
3/16
3/16
1/2
D-60 0-1/8
2
3/16-1/4 1/4
5/8
35 315-375 8-10
15.5
Optional
F
E
0-3/32 2
3/16-1/4
1/4 5/8
35
340-380
8-10
14
up to
V
D-60
0-3/32 3
3/16
3/16-1/4
5/8
35
260-300
8-10
19
250F
Max.
V, H, O E
0-3/32
2
3/16
3/16-1/4 5/8
35 240-300 8-10
17
H
D-90
0-3/32 3
3/16
3/16-1/4
5/8
35
240-300
8-10
22
O
D-110
0-3/32 3
3/16
3/16-1/4
5/8
40
260-300
8-10
32
1
2
3
4
18
See also Recommended Practices for Gas Shielded-Arc Welding of Aluminum and Aluminum Alloy Pipe, AWS D10.7.
F=Flat; V=Vertical; H=Horizontal; O=Overhead.
See joint designs on page 15.
Preheating at excessive temperatures or for extended periods of time will reduce weld strength.
This is particularly true for base metals in heat-treated tempers.
Arc
Approx.
Travel
Filler Rod
Speed
Consumption
(ipm)
(lb./100 ft)
F, H, V
None
3/32
1/16-3/32
3/8
16
70-100
8-10
0.5
None
3/32
1/16-3/32
3/8
20
65-90
8-10
0.5
3/32
None
3/32-1/8 1/8-5/32
3/8
18
110-145 8-10
0.75
H, V
None
3/32
3/32-1/8
3/8
18
90-125
0.75
None
3/32
3/32-1/8
3/8
20
110-135 8-10
0.75
1/8
None
1/8
1/8-5/32
7/16
20
135-175 10-12
H, V
None
1/8
3/32-1/8
3/8
20
115-145 8-10
None
1/8
3/32-1/8
7/16
25
125-155 8-10
3/16
None
5/32
5/32-3/16
1/2
25
190-245 8-10
2.5
H, V
None
5/32
5/32-3/16
1/2
25
175-210 8-10
2.5
None
5/32
5/32-3/16
1/2
30
185-225 8-10
2.5
1/4
None
3/16
3/16-1/4
1/2
30
240-295 8-10
4.5
H, V
None
3/16
3/16
1/2
30
220-265 8-10
4.5
None
3/16
3/16
1/2
35
230-275 8-10
4.5
3/16
1/4
5/8
35
325-375 8-10
9.5
3/16
3/16-1/4
5/8
35
280-315 8-10
9.5
3/16
3/16-1/4
5/8
35
270-300 8-10
9.5
3/16
3/16-1/4
5/8
40
290-335 8-10
9.5
8-10
Welding
Procedures
1/16
3/8
1
2
3
F
Optional
V
up to
H
250F
Max.
O
19
peated short circuits. This metal transfer which is sometimes known as short arc or dip transfer has been perfected for and
is most widely used in the welding of thin gauge steels. Short circuit transfer produces a very low heat input and for this reason has the potential for producing incomplete fusion if used for aluminum. Short circuit transfer is not recommended for MIG
welding of aluminum and has in the past been identified as such in technical publications and welding specifications.
2. Globular Transfer The transfer of molten metal in large drops from a consumable electrode across the arc. This
transfer mode is not considered suitable for welding aluminum and is most predominantly used when welding carbon steel
with C02 shielding gas.
3. Spray Transfer Metal transfer in which molten metal from a consumable electrode is propelled accurately across
the arc in small droplets. When using argon, or an argon rich shielding gas with the MIG process the spray transfer mode can
be achieved once the current increases above the globular-to-spray transition current. When we increase current to beyond
the globular-to-spray transition current the metal transfer moves into spray transfer (The table below shows globular-to-spray
transition currents for a selection of aluminum electrode diameters for welding aluminum). The spray transfer is a result of
a pinch effect on the molten tip of the consumable welding wire. The pinch effect physically limits the size of the molten ball
that can be formed on the end of the welding wire, and therefore only small droplets of metal are transferred rapidly through
the welding arc from the wire to the workpiece. This transfer mode is characterized by its high heat input, very stable arc,
smooth weld bead and very little if any spatter. Because spray transfer has a very high heat input which can overcome aluminums high thermal conductivity, the spray transfer mode is recognized as the preferred mode of metal transfer for welding
aluminum with the MIG process.
Welding
Procedures
Shielding Gas
0.030 (0.8)
100% Argon
90 Amps 5 Amps
0.035 (0.9)
100% Argon
0.047 (1.2)
100% Argon
0.062 (1.6)
100% Argon
This table shows MIG globular-to-spray transition currents for a selection of aluminum
electrode diameters for welding aluminum with pure argon shielding gas.
20
The ability to control bead profile. Using a function called arc control, operators can adjust the width of the
arc cone which lets them tailor the bead profile to the application. A wider bead can help tie-in both sides of
a joint and a narrow bead helps provide good fusion at the root of a joint. A bead of the right size helps to
eliminate excess heat input, over-welding, and post-weld grinding.
3 Superior arc starts. A good pulsed MIG program for aluminum provides more energy at the start of the weld
(which helps ensure good fusion) and then reduces energy to normal parameters for optimal welding
characteristics.
4 Superior arc stops. Todays pulsed MIG equipment provides the technology to ramp down to a cooler
welding parameter to fill in the crater at the end of a weld. This helps to eliminate termination cracking
which can be a serious issue when welding aluminum.
5 The ability to use a larger diameter wire to weld thin gauge material. This can increase the deposition
rate and aid feeding by using a stiffer wire, and can also save money on filler wire. The difference in cost
between a 0.030 wire and a 0.047 wire, for instance, can be considerable.
Welding
Procedures
21
Problem Solving
Obtaining A Stable Arc And Eliminating Erratic Feeding And Burnbacks
Most importantly, purchase Hobart products with controlled diameter, stiffness, cast, pitch, surface finish and low surface
sliding friction. Secondly, always use a welding system that is designed specifically for welding aluminum like the Miller
aluminum welding packages shown on pages 39 and 40 of this brochure. Welding systems like the Miller AlumaFeed have
been specially developed and tested to provide high performance and to help eliminate the typical problems experienced when
welding aluminum.
Check List:
containing materials.
Check that feed rolls, guides and contact tips meet Hobarts specified profile and surface polish recommendations.
They must be free of burrs and machining marks. Use a push-pull wire feeder or spool gun for optimum feedability.
See page 40 in this booklet.
Match the contact tip size to the wire size being used (wire diameter + 10%).
Caution: steel welding wires are produced to different sizes than aluminum. Using a contact tip designed for steel
will cause excessive burn backs with aluminum wire because of inadequate diametrical clearance.
Contact tips must be recessed in the gas cup 1/8 to 1/4 inch for proper gas cooling of the tip and spatter control.
Do not use joggled contact tips.
Prevent overheating of the gun and contact tip by operating at a reduced duty cycle or switching to a
Problem Solving
Purchase contact tips with bore sizes that are 10% larger than the electrode diameter.
Warning: A 3/64 (0.047) diameter aluminum electrode is a different size than 0.045 diameter steel electrode and
takes a different size tip. For instance a 0.052 diameter tip is the correct size for 3/64 aluminum wire.
Contact tips for steel are stamped 0.045 and are not to be used with an aluminum electrode. Purchase
contact tips that have polished bores free from burrs on the inlet and exit ends.
If the contact tip that you are using does have inlet and exit burrs, remove the burrs and polish the bore
Recess the tip 1/8 to 1/4 into the gas cup to promote tip cooling and to reduce spatter and oxide
accumulation that acts like burrs at the end of the contact tip.
Replace all metallic wire guides with non-metallic material. Ask equipment manufacturers for their non-metallic guide kits.
22
A rough surface finish produces fines and aluminum buildup in the groove. Sharp edges and misalignment
Shavings and fines can cause plugged liners and tips, aluminum buildup on the feed rolls distorts the wire
Recommended Design
No Shavings =
good feedability
stable arc
superior arc starts
Note:
Polish all groove surfaces, ensure both rolls are aligned, and always use the lowest drive roll pressure capable
of feeding the wire in order to prevent deformation of the wire during feeding.
Problem Solving
23
Moisture (H O) Moisture within the atmosphere can be a serious cause of porosity under certain circumstances 2
see the calculation of dew point table on page 25. Moisture from other external sources such as compressed air,
contaminated shielding gas or from pre-cleaning operations must also be considered.
Note: Hydrogen gas from these sources can become trapped within the weld deposit and create porosity
Problem Solving
0.7
Solidification
Temp. Range
(1200-1220 F)
Solubility in Liquid
Solubility in Solid
0.036
1220 F
(660 C)
24
Temperature
4532 F
(2500 C)
When experiencing porosity problems the first course of action is to identify the source of hydrogen that is responsible
for producing the porosity.
Purchase MAXAL brand electrodes and rods that have been diamond shaved to eliminate harmful oxides,
Purchase low dew point shielding gases (Argon or Argon/Helium mixtures). Helium mixtures reduce porosity.
Clean base metals by solvent cleaning or etching and then stainless steel wire brushing prior to assembling the weld
joint. A number of commercial cleaners are available but not all are suitable for this cleaning operation. The
solvent must completely evaporate before welding.
Use shielding gas flow rates and purge cycles recommended for the welding procedure and position being used.
Monitor torch angle to ensure air is not being aspirated into the protective inert gas shield. The standard forehand
manufactured with procedures to provide low residual hydrogen containing compounds and then have
been weld tested to the stringent AWS A5.10 standard.
location (outside for example) and allow it to sit in the welding area for 24 hours before welding. Put spacers
between the base metal members (plates for example) to allow air to circulate. Allow the welding material to reach
room temperature prior to welding. Do not attempt to dry metal with an oxyfuel torch since it will only add moisture
to the metal surface and further hydrate the surface oxide already present.
Store unpackaged electrode and rods in a heated cabinet or room to prevent them from cycling through
Problem Solving
dew points, creating hydrated oxide on their surface. See page 25 (calculation of dew point chart).
Check for imperfections within the gas delivery line such as leaks.
Prevent hydrated aluminum oxide.
Avoid cutting fluids and saw blade lubricants.
Avoid grinding disc debris.
25
100
90
*80
70
60
50
40
30
20
10
98F
93F
87F
80F
72F
60F
41F
100
100F
97F
93F
89F
84F
78F
71F
63F
52F
32F
90
90F
87F
83F
79F
74F
68F
62F
54F
43F
32F
80
80F
77F
73F
69F
65F
59F
53F
45F
35F
*70
70F
67F
63F
59F
55F
50F
44F
37F
60
60F
57F
53F
50F
45F
41F
35F
50
50F
46F
44F
40F
36F
40
40F
37F
34F
32
32F
Calculated Dew Point
Warning: If the filler metal or base metal is below the calculated Dew Point condensation will form on the material
causing weld discontinuities.
Problem Solving
Read the Air Temp in the left hand column and humidity along the top of the chart.
*For example: If the air temperature in the welding area is 70F and the humidity is 80%, the intersection of the two shows the
dew point in the area to be 63F. If the metal brought into the welding area is below 63F, moisture will condense on the metal
causing welding quality problems.
One of the most common mistakes that aluminum welding fabricators make is best described with the following example.
Take a large aluminum fabricator located in a warm climate near the ocean.
At night, the building where welding of components is conducted cools down considerably. During the night there is a light rain
and the next morning the relative humidity of the air outside is high (80%). In the morning the welders come to work and the
doors are closed. The temperature in the manufacturing area has slowly cooled down to 60 degrees F. All of the aluminum in
the factory including the welding wire is also 60 degrees F.
Then, someone decides to get some warmer fresh air in the factory and throws the large overhead doors open. In comes
the very warm air from outside and now you have 80 degree F air with 80% relative humidity hitting metal that is 20 degrees
colder. If you look at the chart above you can see that for an air temperature of 80 degrees F and a relative humidity of 80 %
, the metal can only be a maximum of 7 degrees F colder than the ambient air or you will cross the dew point and visible moisture will condense out of the air onto the metal. Once this has happened you have to stop welding until the metal is dried.
Remember that moisture hydrates the aluminum oxide present on all aluminum and may cause irreparable damage.
26
Hot cracking is the cause of most cracking in aluminum weldments. Hot cracking is a high-temperature cracking
mechanism and is mainly a function of how metal alloy systems solidify. There are three areas that can significantly
influence the probability for hot cracking in an aluminum welded structure:
1. Susceptible base material chemistry that effects the probability of cracking.
2. Selection and use of the most appropriate filler metal to help prevent the formation of a crack sensitive chemistry.
3. Choosing the most appropriate joint design that will provide the required dilution of filler metal and base metal in
order to avoid a crack sensitive chemistry in the weld.
Aluminum crack sensitivity curve diagrams are a very helpful tool for understanding why aluminum welds crack and how
the choice of filler alloy and joint design can influence crack sensitivity. The diagram shows the effects of four different
alloy additions - Silicon (Si), Copper (Cu), Magnesium (Mg), and Magnesium Silicide (Mg2Si) on the crack sensitivity of
aluminum. The crack sensitivity curves reveal that with the addition of small amounts of alloying elements, the crack
sensitivity becomes more severe, reaches a maximum, and then falls off to relatively low levels. After studying the crack
sensitivity curves, it is easy to recognize that most of the aluminum base alloys considered unweldable autogenously
(without filler alloy addition) have chemistries at or near the peaks of crack sensitivity. Additionally, the chart shows that
alloys that display low cracking characteristics have chemistries well away from the crack sensitivity peaks.
Based on this information, it is clear that crack sensitivity of an aluminum base alloy is primarily dependent on its
chemistry. Utilizing these same principals, it can be concluded that the crack sensitivity of an aluminum weld, which
is generally comprised of both base alloy and filler alloy, is also dependent on its chemistry. With the knowledge of the
importance of chemistry on crack sensitivity of an aluminum weld, two fundamental principals apply that can reduce
the incidence for hot cracking. First, when welding base alloys that have low crack sensitivity, always use a filler alloy
of similar chemistry. Second, when welding base alloys that have high crack sensitivity use a filler alloy with a different
chemistry than that of the base alloy to create a weld metal chemistry that has low crack sensitivity. When considering
the welding of the more commonly used 5xxx series (Al-Mg) and the 6xxx series (Al-Mg-Si) aluminum base alloys, these
principals are clearly illustrated.
Problem Solving
Al-Cu
0
Al-Mg
0
Al-Mg Si
2
0
1
27
The aluminum/magnesium/silicon base alloys (6xxx series) are of a chemistry that makes them crack sensitive because
the majority of these alloys contain approximately 1.0% Magnesium Silicide (Mg2Si), which falls close to the peak of the
solidification crack sensitivity curve. The Mg2Si content of these materials is the primary reason there are no 6xxx series filler
alloys. Using a 6xxx series filler alloy or autogenously welding would invariably produce cracking problems in the weld. During
arc welding, the cracking tendency of these alloys is adjusted to acceptable levels by the dilution of the base material with
excess magnesium (by use of the 5xxx series Al-Mg filler alloys) or excess silicon (by use of the 4xxx series Al-Si filler alloys).
Particular care is necessary when TIG welding on thin sections of this type of material. It is often possible to produce a weld,
particularly on outside corner joints, without adding filler material by melting both edges of the base material together. These
types of techniques should be avoided as the absence of filler metal will produce welds that are extremely susceptible to
cracking.
The Effect of Welding the 6xxx Series Base Metals without Filler Metal Addition (Autogenously)
Below we see two welds made on a 6061-T6 plate one weld with a 4043 filler alloy and one weld without any filler alloy added.
Visual Inspection of two welds made with the TIG process on base alloy 6061-T6
Note: the extent of cracking within a weld without filler metal will be dependant on the degree of shrinkage stress
that is developed during the welding operation. The addition of filler metal lowers the crack sensitivity of the weld
and dramatically reduces the probability of hot cracking.
When arc welding these base metals the addition of filler metal is required in order to produce a chemistry in the weld that
will create consistent crack free welds.
a. Weld joint designed with no bevel resulting in significant base metal melting
Note: If we check the hot crack sensitivity curves, on page 26, we will see that 1.8% Mg has high crack sensitivity and 3.4%
Mg has comparatively low crack sensitivity. (On this premise it is safe to say that the weld with the square edge preparation is
very likely to crack.)
28
Problem:
Solution: The filler metal choice has an effect on shrinkage stress. Silicon filler metals (4xxx) have lower
solidification and reduced cooling shrinkage rates than Mg filler alloys. Therefore, 4xxx filler alloys have lower
shrinkage stresses and produce reduced stress cracking.
Problem:
Excessive base metal melting and increased shrinkage stresses resulting from too slow a travel speed.
Solution: Increase travel speed to narrow the heat affected zone and reduce melting.
Problem: A fillet weld that is too small or concave may not withstand shrinkage stresses, and crack.
Solution: Increase fillet size and/or adjust weld profile.
Problem: A weldment that is highly restrained during the welding process may develop excessive residual
Solution: Remove excessive restraint and/or apply a compressive force during welding.
Problem: Termination cracking at the end of the weld bead (crater cracks).
Solution: Termination cracks can be reduced by increasing travel speed at the termination of the
weld, by doubling back for a short distance at the end of the weld or by re-arcing the wire several times
into the puddle to add additional weld metal to the solidifying weld pool. Welding equipment with a
Crater Fill feature is the best method of preventing this problem. For this reason Miller aluminum
welding packages are provided with crater fill as a standard feature (see page 39 and 40).
4xxx series filler metals produce less weld discoloration, spatter and smut than 5xxx series filler metals. The Magnesium in
5xxx alloys vaporizes in the arc and condenses as a black powder next to the weld bead. The Mg in 5xxx alloys has a lower
vapor pressure than either silicon or aluminum when melted in the arc. This lower vapor pressure of Mg increases vaporization
and causes some disintegration of the transfering droplet as separation from the tip of the electrode occurs. Small spatter
and vaporized Mg are thrown outside of the arc plasma column. Increased black smut and spatter are encountered next to
the weld bead with 5xxx filler metal alloys.
Hobart manufactures all of its products to minimize weld discoloration, spatter, and smut from contamination.
Introduction of oxygen into the shielding gas envelope via air, moisture, and contaminants will increase the burning
(oxidation) of the filler metal producing discoloration, spatter, and smut.
Problem Solving
Decrease gun angle (the typical forehand angle is 10-15 from perpendicular).
Shut the welding guns cooling water off when the gun is not in use.
29
Keep electrode covered while on the welding machine or in storage to minimize oxidation,
moisture condensation, and other contamination.
Penetration and fusion are controlled by the welder, the weld joint design, the weld procedure, the welding equipment,
and the shielding gas characteristics.
Problem Solving
30
Increase welding amperage and reduce arc travel speed (while staying in front of the puddle).
Decrease arc length and/or increase amperage to increase penetration.
For better fusion, solvent clean and then wire brush base metal prior to fit-up to remove hydrocarbons
and oxides. Fusion will not occur across an oxide barrier.
Remove all edges that have been cut with a band saw.
For heat treatable aluminum alloys, remove all edges that have been cut by melting.
Use stringer beads, do not weave.
Redesign the weld joint to improve access to the root, incorporate a 60 bevel to allow better
penetration and wider fusion in the weld root.
The Aluminum Association deals briefly with this subject in their publication entitled, Welding Aluminum: Theory and Practice.
They state that the welder learns to set the correct arc length mostly by sight and sound, which is true. But, we have expanded
on this subject here in order to provide a better understanding of the science involved and to give more guidance on what the
effects are of changing the voltage and amperage in the welding process.
The voltage, amperage, and travel speed selected to make a MIG weld determines the shape, size, and penetration of the weld
bead. The shape, size, and penetration of the weld bead required for a specific welded component varies based on the weld
joint design, section sizes of the components being welded and on the mechanical strength requirements of the finished weldment. Other considerations such as visual requirements are also to be considered. Describing the numerous physical effects
of varying arc voltage and amperage during welding is best done using a chart. We have done this by assuming that the travel
speed is held constant. The results shown in the chart are governed by a simple electrical formula which reads as follows:
Welding Characteristic
Lower Voltage
Higher Voltage
Arc length
Shorter
Longer
Higher
Lower
Narrower
Wider
Deeper
Shallower
More
Less
Arc sound
Crackling
Humming
Less
More
Spatter
Welding Characteristic
Arc voltage/amperage
Lower
Higher
Rippled
Smoother
More
Less
Shallower
Deeper
Less
More
Smut
Problem Solving
31
Butt
Inadequate Penetration
Excessive Convexivity
Insufficient Throat
Undercut
Problem Solving
Effect on Weldment
Reduced weld
Increase heat and/or
strength and decrease arc length,
increased sensitivity decreasing travel speed,
to crack propagation forehand torch angle
Reduced fatigue
Increase arc length
strength and/or torch angle
Reduced mechanical
Decrease travel speed
properties and/or arc length
Reduced mechanical
Change torch angle
properties and/or torch position
Decrease arc length
Match base metals with
equal thermal conductivities
Concentrate the arc on the
base metal with the higher
thermal conductivity
Reduced mechanical
Change torch position to
properties & fatigue compensate for dissimilar
strength section thicknesses or
dissimilar thermal
conductivity sections
Overlap
Reduced fatigue
Increase welding heat
strength
Use correct torch angle
Wire brush to remove
heavy oxide layers
Band saw and belt sand a cross sectional sample of the weld joint.
Heat up sample in hot water. Spray the cross section with Easy Off oven cleaner.
Let stand for 5 minutes and rinse.
Note: Easy Off oven cleaner contains caustic soda which etches the cross
section of the sample showing the weld bead profile and penetration.
32
1 Using the plunger type rather than the wraparound guided bend jig - The AWS D1.2 code is very clear in stating
that the wraparound bend jig is the preferred method of bend testing aluminum weldments and even provides an
explanation in the commentary as to why. The plunger-type test jig may prove suitable for some of the low strength
base materials. However, it is MAXALs opinion that the wraparound bend jig should be used for all aluminum alloys.
2 Incorrect Preparation of the Bend Test Samples - This may be as simple as not applying the required radius to the
edges of the test specimen or producing specimens of an incorrect size. However, it is most often associated with
not applying the alloy specific special bending conditions contained within the code. This paragraph is entitled
Special Bending Conditions M23, M24, M27 Base Metal, and F23 Filler Metal. If the instructions contained within
the special bending requirements paragraph of the AWS D1.2 Code are not followed you may experience major
problems during bend testing. Because of very different as-welded mechanical properties within the different
groups of materials (aluminum alloys), different alloy groups must be tested in very different ways. Some of the
variations that are alloy-group specific are: reducing the specimen thickness to 1/8 inch prior to bending, subjecting
the specimen to heat-treatment after welding in order to anneal the specimen prior to testing, the use of alloy-specific
and temper condition bend diameters, and even a restriction associated with the maximum amount of time permitted to
elapse prior to testing is applied to one particular alloy group. Unfortunately, not following these special requirements
correctly and consequently not applying the correct requirements to the specific alloy being tested appears to be one of
the primary causes for failing guided bend tests conducted on samples that appear to be of sound integrity.
Correct
3/8
B= (1/2)A
Correct
Problem Solving
1/16 Max
t
A
1/8 Max
1/8
Roller
Incorrect
THICKNESS A
B MATERIALS
3/8
1 - 1/2
3/4
M21 & M22
t 4t 2t
1/8
2 - 1/16
1 - 1/32
M23 & F23
t(<1/8) 16-1/2t 8-1/4t
3/8
2 - 1/2
1 - 1/4
M25
t 6-2/3t 3-1/3t
3/8
3
1 - 1/2
M24 & M27
t 8t 4t
33
1 The code will typically provide minimum dimensions for groove weld test plate size. You must comply with this requirement;
in fact, if practical, use a larger test sample than specified. This will provide for superior heat sink capacity and lower the
possibility of excessive overheating and prolonged time at temperature within the heat-affected zone.
2 Comply with the preheating and interpass temperature requirements of the code, which for this type of material specifies
250 deg F as the maximum preheat and interpass temperature. Try to conduct the certification testing without preheating,
or at lower preheating temperatures (150 deg F), and allow the base material to cool to well below the maximum interpass
temperature before welding is resumed.
3 A major contributor to the overall heat input of a weld is the travel speed during the welding process. For this reason,
it is preferable to select a welding sequence and technique which makes use of faster stringer beads, do not use slower
weaving techniques.
Product Thickness
M25
5083-O
5083-H112
Sheet 0.051-1.500
Plate 0.051-1.500
Minimum Tensile
Strength (Ksi)
40
40
5083-H116
Plate 1.50-3.000
39
24
M23
Problem Solving
6061 - T51, T6
6061 - T62, T651
Note: These figures are extracted from the AWS D1.2 Structural Welding Code for Aluminum
Welding Tensile Strength of Aluminum Alloys Table.
Test Plate
t
1/4
A - Reduced Length
L - Length
W - Reduced Width
c w
C - Grip Width
t - Thickness
1/4
34
1/4
A
L
1/4
AWS A5.10 establishes specific chemistry requirements for MIG and TIG consumables. These have been evaluated to
establish safety criteria for each alloy. The designation of ER for MIG products and R for TIG products establishes the
specification chemistry limits that have been approved for each welding consumable. Some aluminum alloys are approved
for TIG welding processes and not for MIG processes. The MIG process produces more metallic vapors than the TIG process
and therefore has more restrictions on chemistries. AWS A5.10 identifies these analysis limits as ALLOY CLASSIFICATIONS.
A non-standard term which does not have a consistent definition. See Certificate of Compliance or Certificate of Conformance.
A statement that the product meets the requirement of the AWS specification/classification. The Maxal certificates of
compliance include a chemical analysis of a similar lot processed in the year. Maxal certificates of compliance can be
found at maxal.com.
A test report where there is specific reference to the tests being conducted on the actual material supplied. The CMTR
may contain results of some or all of the tests required for classification, or other tests as agreed upon by the purchaser
and supplier. See Annex D of AWS A5.01 for more details. Maxal Certified Material Test Reports specific to every lot
shipped can be found at maxal.com.
Specifications
35
AWS A5.10
AWS D1.2
The requirements for each welded structure must be fully determined by the purchaser. The AWS A5.01 specification
allows manufacturers to purchase aluminum electrode and rods to four lot classifications (S1 through S4). Each classification
ensures that the producer of the consumable meets specific requirements. Classification S1 is the lot requirement as specified
in the electrode manufacturers quality assurance manual. S2 through S4 specifies items such as production sequences and
heat or controlled chemistry reporting of alloy composition analysis, etc. The specification specifies various levels of testing for
the consumable. The levels of testing vary from Schedule F through K. Schedule F is the consumable manufacturers base standard. Levels G through K give other specific requirements. One of the most frequently used schedules for critical, dynamically
loaded weldments is schedule J. Schedule J requires that each lot of material shipped per the requirements of this specification
be tested to the usability test found in AWS A5.10 (weld test and x-ray for MIG electrode or bead on plate test for TIG rods).
AWS A5.10 Specification for Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods
This specification provides requirements governing the manufacture, alloy classification, identification, testing procedures
and requirements, and packaging of aluminum electrodes and rods. The customer specifies the product requirements in AWS
A5.01. The consumable manufacturer produces the product to the order requirements ensuring conformance to AWS A5.10
and identifies the product classification on the product label. Key elements of the A5.10 specification are the product quality
test procedures and quality requirements. For example, the test procedures for 1/16 inch diameter and smaller electrodes
state that they are to be welded in the overhead weld position to maximize the capture of porosity generated by the welding
electrode. This ensures a very thorough testing of the electrodes quality when radiographically tested.
All manufacturers of aluminum structures should consider using this code for the control of their welding operations.
D1.2 provides the manufacturer with three fundamental requirements for establishing a quality control system. The three
fundamentals are qualified welding procedures, requirements for qualifying welders, and acceptance criteria for the production
and inspection of weld quality. Quality and inspection standards are provided for statically and cyclically loaded structures.
It is critical that the manufacturer understand the customers purchase order requirements for the welded structures he is
producing and establish the required quality control system for his welding operation to meet those requirements.
Specifications
The AWS specifications establish a complete system from order requirements to final fabricated product to ensure that the
critical characteristics of the end product are met. The AWS specifications play a fundamental role in this supply chain process
to assure consistent quality performance on everyones part. Purchase of high quality Hobart aluminum welding consumables
plays a major part in meeting the requirements of any aluminum welding fabricators quality assurance system.
36
Information Sources
Welding Design Information and Technical Assistance
American Welding Society
www.aws.org
www.aluminum.org
www.ansi.org
www.astm.org
ASTM B 918-01, Standard Practice for Heat Treatment of Wrought Aluminum Alloys
ASTM E 142, Standard Method for Controlling Quality of Radiographic Testing
ASM International
www.asminternational.org
Information
Sources
37
Conversion Tables
Approximate conversion values for English to metric and metric to English
To Convert From English to Metric
Multiply By
Divide By
inches
2.540 centimeters
inches
25.40 millimeters
feet
0.3048 meters
yards
0.9144 meters
ounces (adp)
28.35
grams
troy ounces
31.10
grams
pounds (adp)
0.4536
kilograms
short tons
0.9071
metric tons
fluid ounces
29.57
milliliters
quarts
0.9464 liters
gallons
3.785 liters
pounds/in2
Information
Sources
Fraction
Decimal
Millimeters
.023
0.6
2083
4592 (1400 m)
23
.030
0.8
1215
2678 (816 m)
20 1/2
.035
0.9
900
1984 (605 m)
19
.040
1.0
704
1552 (473 m)
18
3/64
.047
1.2
520
1146 (349 m)
17
.059
1.5
308
679 (207 m)
15
1/16
.062
1.6
290
639 (195 m)
14
.079
2.0
172
379 (116 m)
12
3/32
.093
2.4
130
287 (87 m)
11
1/8
.125
3.2
70
154 (47 m)
5/32
.156
4.0
45
99 (30 m)
6 1/2
3/16
.187
4.7
31
68 (21 m)
4 1/2
1/4
.250
6.3
20
44 (13 m)
38
The
Commitment
Maximized electrode feedability through precise diameter size control, wire columnar strength
control and low surface sliding friction
Maximized welding consistency through specific controlled chemistries and wire diameter
control to 1/10th of the AWS standard
Minimized welding porosity through process control and x-ray testing
Minimized welding smut, spatter and weld discoloration through electrode surface oxide and
cleanliness control
Optimized packaging - plastic wrapped electrodes and rods in unique high strength reusable cartons
Customer Support
Same day shipment from inventory
Competitive product pricing
Large finished goods inventory
Technical brochure
Training seminars (next page)
Technically trained sales network
Factory based welding engineers and metallurgists available for assistance and problem solving
For more information, go to the Hobart web site at www.hobartbrothers.com
39
Welding Procedures:
Safety procedures
WPS preparation
Sample preparation
Pre-weld inspection
Welding machine set up
41
Millermatic 350P
Cost effective, light industrial
all-in-one MIG/Pulsed MIG solution
with easy-to-use interface for aluminum
and steel wire welding on material up
to inch thick. Features built-in
running gear for mobility.
AlumaFeed Synergic
Aluminum System
Dedicated industrial-fabrication
aluminum welding solution with
advanced welding features that can
handle larger weldments. Its lightweight
push-pull feeder can easily be carried
up to 135 feet from the power source
for added portability.
42
To place an order:
Hobart Brothers Co.
Phone: 800-424-1543
Fax: 800-541-6607
$15 USD
CRACK SENSITIVITY The Probability of Hot Cracking - this rating is established through use of
crack sensitivity curves (Developed by Alcoa) and the consideration of filler metal and base metal
chemistry combinations. There are levels of various alloying elements within aluminum that have
been identified as seriously affecting hot cracking susceptibility during weld solidification. This
rating is primarily based on the probability of producing a weld outside these crack sensitive
chemistry ranges.
STRENGTH Ratings are for fillet weld and groove weld strength in the as welded condition.
Groove welds Any specified filler metal with a rating can provide minimum transverse tensile
strength in groove welds that will meet the as-welded strength of the base material.
Fillet welds Ratings provided are for fillet weld shear strength.
DUCTILITY This characteristic of the completed weld may be of consideration if forming
operations are to be used on a completed weldment during fabrication.
Note: Testing procedure requirements for guided bend tests may need to be adjusted to
accommodate the varying ductility of filler metals (AWS D1.2).
CORROSION RESISTANCE This variable may be a consideration for some environmental
conditions. The rating is based on exposure to fresh and salt water environments and is not
associated with a specific chemical exposure. It gives an indication as to the possibility of galvanic
corrosion due to the difference in the electrode potential between the base metal and the filler
metal. For consideration for other environmental and chemical exposures contact MAXAL.
ELEVATED TEMPERATURE SERVICE This rating is based on the reaction of some filler metals
when exposed to sustained elevated temperature: 150F to 350F (66C to 180C). If 5xxx
series base metal or filler metal with more than 3% magnesium content are subjected to
prolonged exposure to these temperatures, precipitate can form within them that is highly anodic
to the aluminum-magnesium matrix. It is this continuous grain boundary network of precipitate
that produces susceptibility to stress corrosion cracking (SCC) and the potential for premature
component failure.
COLOR MATCH AFTER ANODIZING Base metal and filler metal color match after post-weld
anodizing can be of major concern in cosmetic applications. Some filler metals closely match the
base metal color after anodizing and others will react to the anodizing process by changing to a
color very different to that of the base metal.
POST WELD HEAT TREATMENT This rating applies to the ability of a weld to respond to post-weld
heat treatment in the form of solution heat treatment and artificial aging. An A rating indicates
that the filler metal is heat treatable and will therefore respond to post weld heat treatment even
without dilution of the base metal. A B rating indicates that the filler metal is not heat treatable.
However, it may be used for applications requiring post weld heat treatment but with the
understanding that the weld may or may not acquire substantial increase in strength dependent
on the joint design, welding procedure, and resultant amount of dilution of base metal obtained
during welding. A C rating requires consultation with MAXAL. No rating indicates that the filler
metal is not heat treatable and that it should not be used for applications requiring post weld heat
treatment as it may result in substantial reduction in weld performance.
TOUGHNESS This rating applies to the ability of an aluminum weldment to deform plastically in
the presence of stress raisers without low-energy initiation and propagation of cracks. The most
useful test data is from tear resistance testing expressed in unit propagation energy of measured
crack lengths. In structural design, notch toughness is becoming more emphasized by designers
to facilitate the ability to inspect highly stressed structures and find cracks in weldments before
catastrophic failure occurs. It may also be a design consideration if fatigue and impact loading are
factors directly associated with a weldment.
METAL GROUPS
Pure
Aluminum
BASE
METAL
1100, 1060,
1070, 1080,
1350
FILLER
METAL
Aluminum Manganese
Aluminum - Copper
3003,
Alclad 3003
2219
2014, 2036
AL-Mg2Si
AL - Zinc
6061,6005
6063,6070
6151,6201
6351,6951,6082
7005, 7021
7039, 7046
7146
710.0, 711.0
Aluminum - Magnesium
511.0, 512.0
513.0, 514.0
535.0
5154, 5254
5086,
5083,
5456, 5383
5005, 5050
5052, 5652
3004,
Alclad 3004
5454
AL - Castings
METAL GROUPS
WELD METAL
PROPERTIES
319.0, 333.0
354.0, 355.0
C355.0, 380.0
413.0, 443.0
444.0, 356.0
A356.0, 357.0
359.0
7005, 7021
7039, 7046
7146
710.0, 711.0
6061,6005
6063,6070
6151,6201
6351,6951,6082
5454
511.0, 512.0
513.0, 514.0
535.0
5154, 5254
5086,
5083,
5456, 5383
5005, 5050
5052, 5652
3004
Alclad 3004
3003,
Alclad 3003
2219
2014, 2036
1100, 1060, 1070,
1080, 1350
2319
4043/4943**
4145
4043/4943**
4145
A356.0
A357.0
5356
4043/4943**
4145
5183
5356
5554
5556
5654
4043**
4145
4943**
5183
5356
5554
5556
5654
5183
5356
5554
5556
5654
5183
5356
5554
5556
5654
5183
5356
5554
5556
5654
4043/4943**
5183
5356
5554
5556
5654
1100
4043/4943**
4145
5183
5356
5554
5556
1100
4043/4943**
4145
2319
4043/4943**
4145
2319
4043/4943**
4145
1100
1188
4043/4943**
BASE
METAL
FILLER
METAL
WELD METAL
PROPERTIES
B
A
A
A
A
A
A
A
A
B
A
B
A
A
A
B
A A
A A
A A
A
C
D
C
D
B
C
A
B
A
A
C
B
B
A
A
B
C
A
B
A
C
B
A
A
A
A
A
A
A
A
A
A
A
A
B
A
B
A
A
C
D
C
D
B
C
A
B
A
A
C
B
B
A
A
B
C
A
B
A
C
B
A
A
A
A
A
A
A
C B BA A A
D A A B A A
B A B A A
D B BA A A
A A B A A
B
A
B
B
A
A
A
B
B
C B B A A A
D A A B A A
C
B
A
C B B A A A
D A A B A A
A D C A A
B A B A A
B B A A A
D
C
C
A
B
C A A
D B A
C A A
B
A
A
A
B A B
A
A
A
A
A
B
A
B
A
A
C B BA A A A
D A A B A A A
C A A A A A A
D
C A D C A A
D
A
B A B A
A
B B A A
B A B A
C A D
D A C
A C
B A
B B
C A A
D B A
C A A
B
A
A
A
B A B
C B B A A A A
D A A B A A A
D A A A A A A
C A A A A A A
D
D A B A A A A
D A D C B A
B A B B
A
D B D C B A
A
D
B B A
A B B
C C
B B A
C C
C A D
D B C
C A C
B B A
A B B
B
A
B
B
B
C
D
C
B
A
A
A
B
A
B
A
A
B
C
A
C
D
B
A
A
B
A
C
A
A
A
A
A A A
A
A
A
A
A A
B A A B A
A A BA A
B
B A A B A
B
D
A
B
B
C
B B
C
C
A
B
C
A
C
C
B
A
A
B
A
A A
B
C
A
C
B A B
C
B
B
A
D
B
A
B
B
A
A
C
A
B
A
A
C
A
B
A
A
C
A
B
A
A
A
C
A
B
A
B
C
A
C
A
B
C
A
C
A
B
C
A
C
C
A
B
C
A
C
B
A
A
B
A
C
D
C
B
A
A
A
A
A
A
A
B
A
A
A
A A
A
B
A
A
A
A
A
B BA B
B
B
C
B
A
B
C
A
B
A
A
B
B
A
A
B
A A A
A
B
B
A
B
B
B
B
C
B
A
B
C
A
B
A
A
B
A
A
A
B
A A A
A
B
B
A
B
B
B
B
C
B
A
B
C
A
B
A
A
B
A
B
A
B
A A A
A
B
B
A
B
B
B
B
C
B
C
A
A
A
B
C
A
C
A
B
B
A
A
B
A
B
A
B
B
A
B
A
A
A
A
A
A
A
B
A
A
B
A
B
B
B
B
A
B
B
C
B
C
A
A
A
B
C
A
C
A
B
B
A
A
B
A
B
A
B
B
A
B
A
A
A
A
A
A
A
B
A
A
B
A
B
B
B
B
A
B
B
C
B
C
A
A
A
B
C
A
C
A
B
B
A
A
B
A
B
A
B
B
A
B
A
A
A
A
A
A
A
B
A
A
B
A
B
B
B
B
A
A A B A
A A B A
B A A B A
A C C A A
B A B
A
B B A
A
D
B
A
A C C A A
A
B A B
A
B B A
D A C C A A
B B A B
A
A B B A
A
D
B
A
B A B
B B A B
B A B
D
A
B
C
C
D
C
C
A
B
A A A A
C A A
D B A
B
B
B
B
C
D
D
B
A
C
A
B
C
C
C
B
A
A
A
B
A
A
B
B
A A A A
B A A
C B A
B
A
D B A AA A
D A A BA A
B A A A A A A
D B C B C A
B
D A B C B A
A
C A A A A A A
D B C B C A
B
D A B C B A
A
A
1100
A
1188
D
4043/4943**
B B A A A
A A B A A
B
A
B
C
A
BA A A
A B A A
BA A A B
A A A A
A B A A
D
D
A
D
D
A
D
D
C
C
A
B
A
C
D
B
B
A
A A A
A A
B A
A
C
A
C
C
B C
A
B
A A A A
B A A A A
D A A B A A
A A B A A
D A A C B A
A A A A A A A A
2319
B C B C A
B D 4043/4943**
A D
A B C B A
4145
2319
4043/4943**
2014, 2036
4145
1100,1060,1070,
1080,1350
C
D A D D A A
D
B B A C C
A
A B B B C
A
C C A B A A
B B A C C
A
A
1100
D 4043/4943**
D
4145
D
B
A
B
B
A
B B
A
A B
A A A A
A
BB
B
A B
B
B B
A
A B
B
A A
B
B B
A
A A
A
BA
A A
A
A A
A
A
BA
A
A B
C B A
A
BA
A
A A
A A A A
BA
A
A
A B
1100
4043/4943**
4145
5183
5356
5554
5556
B
A
B
B
B
B
A
B
B
B
B
A
B
B
B
D
B
A
B
B
B
B
A
A
A
A
A
A
B A A
A A B
B C
B A A
B C
B
A
A
B
A
A
A
A
A
A
A
A
A
A
A
B
A
B
B
B
A
A
B
A
B
A
B
C
A
C
B
A
A
B
A
A
A
A
A
A A A
A
A
A
A
B
A
B
B
B
C
A
C
A
A A A
C
A
B
B
B
D
B
B
B
A
A
A
A
B
B
A
B
B
B
A
A
B
A
B
A
B
C
A
C
B
A
A
B
A
A
A
A
A
A
A
A
A
A
B
B
A
B
B
B
B
B
C
B
C
A
B
C
A
C
B
A
A
B
A
C
C
B
C
B
A
A
A
A
A
B
A
B
B
B
B
B
C
B
C
A
B
C
A
C
B
A
A
B
A
A
A
B
A
A
B
C
A
B
A
A
B
B
B
A
B
A
A
A
A
B
A
B
B
A
A
A
A
A
A
A
A
A
A
A
B
A
A
B
A
B
B
B
B
A
A
A
A
A
B
B
A
B
A
A
B
A
B
B
B
B
A
B
B
B
B
A
A
B
A
B
A
A
B
A
B
A
A * BA
B B
A B
A A
B B
A A
B B
A B
A A
B B
A A
5183
5356
5554
5556
5654
A
B
C
A
C
A
B
C
A
C
*
*
A
B
C
A
C
A
B
C
A
C
A
A
B
A
B
A
A
B
A
B
A
A
A
A
B
A
B
A
A
B
A
B
4043/4943**
5183
5356
5554
5556
5654
5005, 5050
5052, 5652
3004,
Alclad 3004
3003,
Alclad 3003
2219
5356
5183
5556
5356
5183
5556
5356
5183
5556
B
A
A
Note: Any strength rating will meet the minimum transverse tensile
strength requirements of AWS D1.2, a blank rating typically will not.
B
B
A A
B
B
5183
5356
5554
5556
5654
5086,
5083,
5456, 5383
B
A
B
A
A A
A A
A A
A
C
D
C
D
A D C B A
A A A A
B
D B D C B A
A A
A B
B C
A A
BC
AD
B
A
A
B
A
B
A
A
A
A
A A A
A
A
A
A
A A
B
B
A
B
B
A
D
A
B
B
C
B
C
B
A
A
A
A
A
A A
A D
C
A
B
C
A
A
B B A C B
C
A
B
B
B
B
C
A
B
C
A
C
A
B
A
B
A
A
A
B
A A
A A
A A
A
5183
5356
5554
5556
5654
C
D
C
D
B
A
A
A
A
A
B
A
B
B
A
D
C
A
B
C
A
C
A
B
B
B
A
A
A
B
B A
A
A A
A
A A A A
B A
A
A A
A
4043**
4145
4943**
5183
5356
5554
5556
5654
C
C
C
C
C
B
A
B
B
B
B
A
A
A
A
A
B
A
D
C
A
A
A
B
A
B
A
A
A
A
A
B
A
A
A
A
A
A
A
A
A
A
A
B
A
A
4043/4943**
4145
5183
5356
5554
5556
5654
C
C
C
C
B A A A A A A A
C
D A C B B A A A D
C 4043/4943**
4145
D
A
A356.0
A357.0
B
5356
6061,6005
6063,6070
6151,6201
6351,6951,6082
5454
511.0, 512.0
513.0, 514.0
535.0
5154, 5254
Example:
Welding 5454 base material that will be used as a
support bracket for an industrial heater This
weldment will be subjected to sustained elevated
temperature of 250 to 300F (121 to 149C).
1. As the welded component is operating at
temperature above 150F (66C).
Elevated TEMPERATURE is the most
important weld metal property.
2. Left hand column 5454 (fifth from top), and top
row 5454 (fifth from right).
3. See insert picture of intersecting row and column
(On Right).
4. There is only one row that has a rating for
elevated temperature.
5. For this particular application we only have one
filler metal that is suitable for this application,
and that is filler metal 5554. All the other filler
metals within the box have a blank rating for
elevated temperature which indicates that they
are not suitable for this particular welding
application.
2319
4043/4943**
4145
413.0, 443.0
444.0, 356.0
A356.0, 357.0
359.0
319.0, 333.0
354.0, 355.0
C355.0, 380.0
7005, 7021
7039, 7046
7146
710.0, 711.0
5454
5183
5356
5554
5556
5654
A
A
B
A
B
A
B
C
A
C
B
A
A
B
A
A
B
B
A
A A A
A
B
B
B
B
A
B
B
B